Manager / Quality Head – Quality Control
JSW Cement Limited, Nandyal
To perform chemical analysis of raw materials, fuels, clinker, cement and other process samples using laboratory analytical instruments, ensuring timely and accurate results to support process control and maintain product quality. The Chemist is responsible for laboratory testing, equipment maintenance, quality assurance activities, and compliance with safety and quality management systems while working in both shift and general shift schedules.
- Perform routine chemical analysis of limestone, laterite, bauxite, iron ore, raw meal, kiln feed, clinker, gypsum, fly ash, slag, pozzolana, cement, coal, pet coke, AFR, and other raw materials.
- Carry out analysis using XRF, wet chemistry, titration, gravimetric methods, and instrumental techniques.
- Prepare fused beads and pressed pellets for XRF analysis.
- Verify analytical accuracy using certified reference materials (CRMs).
- Ensure timely reporting of laboratory results.
- Monitor chemical parameters including:
- Lime Saturation Factor (LSF), Silica Modulus (SM), Alumina Modulus (AM)
- Free Lime, LOI, Insoluble Residue
- CaO, SiO₂, Al₂O₃, Fe₂O₃, MgO, SO₃, Na₂O, K₂O, Chloride
- Compare analytical results with quality control limits.
- Immediately report abnormal results to Production, CCR and Quality Management.
- Assist in process adjustments to maintain consistent clinker and cement quality.
3. XRF Laboratory Operations
- Operate and monitor XRF spectrometer.
- Perform daily calibration and standardization.
- Prepare calibration samples and conduct drift correction and performance verification.
- Troubleshoot basic instrument issues.
- Coordinate with service engineers for preventive maintenance.
- Conduct wet chemical analysis as per SOPs.
- Prepare and standardize laboratory reagents.
- Perform volumetric and gravimetric analysis.
- Validate XRF results through wet chemistry when required.
- Receive and identify production samples.
- Dry, crush, pulverize, sieve and homogenize samples.
- Operate sample preparation equipment safely.
- Prevent sample contamination and mix-up.
6. Physical Testing Support
- Assist in cement physical testing, including:
- Blaine Fineness, Residue / Sieve Analysis
- Initial & Final Setting Time, Soundness
- Mortar Compressive Strength, Standard Consistency, Density (as required)
7. Data Management & Documentation
- Record laboratory data accurately in LIMS, ERP or laboratory registers.
- Prepare daily, weekly and monthly laboratory reports.
- Maintain calibration records, QC charts and analytical logs.
- Ensure traceability of all laboratory samples and results.
8. Instrument Maintenance
- Perform daily instrument health checks and monitor laboratory equipment performance.
- Maintain calibration schedules.
- Coordinate preventive and breakdown maintenance.
- Ensure availability of laboratory consumables and chemicals.
- Follow ISO 9001 quality management requirements.
- Participate in internal quality audits.
- Maintain laboratory documentation according to QA procedures.
- Support method validation and uncertainty evaluation.
- Participate in inter-laboratory comparison and proficiency testing.
- Monitor raw mix chemistry and kiln feed quality.
- Support kiln optimization through timely laboratory feedback.
- Monitor clinker quality trends and cement quality before dispatch.
11. Shift Responsibilities
- Handle all laboratory activities independently during assigned shifts.
- Ensure continuous sample testing and maintain shift handover records.
- Coordinate with CCR operators and production personnel.
- Escalate quality deviations immediately.
12. General Shift Responsibilities
- Assist in laboratory planning, scheduling and review of analytical data.
- Train laboratory technicians and trainee chemists.
- Prepare SOPs and work instructions.
- Support laboratory improvement projects.
- Participate in quality meetings and process review discussions.
- Coordinate with production, mines, and raw material handling teams to ensure compliance with quality specifications.
13. Safety & Housekeeping
- Follow laboratory safety procedures and use appropriate PPE.
- Handle acids, alkalis, gases and chemicals safely.
- Ensure proper storage and labeling of chemicals.
- Maintain 5S standards in the laboratory.
- Dispose of chemical waste according to environmental regulations.
- Report unsafe conditions, incidents, and near misses.
Educational Qualifications
- B.Sc. or M.Sc. in Chemistry, Analytical Chemistry, Industrial Chemistry, or a related field.
- Additional training in Cement Chemistry or Analytical Instrumentation is preferred.
- 5–10 years of experience in a cement plant chemical laboratory.
- Experience with XRF operation, wet chemistry and laboratory quality systems.
- Familiarity with LIMS/ERP systems is an advantage.
- Willingness to work in rotating shifts and general shift assignments as per requirement.
- Strong knowledge of cement manufacturing chemistry.
- Expertise in XRF analysis and sample preparation.
- Knowledge of wet chemical analysis and analytical calculations.
- Familiarity with ASTM, BIS (IS), EN and ISO standards for cement testing.
- Proficiency in MS Excel, Word and laboratory data management software.
- Good analytical, troubleshooting, and communication skills.
- Ability to work independently and as part of a multidisciplinary team.
